Bendix Bw1597 Users Manual Sd082403

: Bendix Bendix-Bw1597-Users-Manual-651143 bendix-bw1597-users-manual-651143 bendix pdf

Open the PDF directly: View PDF .
Page Count: 16

Download
Open PDF In Browser	View PDF

SD-08-2403

®

Bendix® AD-1™ and AD-2™ Air Dryers

AD-1™ AIR DRYER

AD-2™ AIR DRYER

FIGURE 1

The air dryer collects and removes moisture and
contaminants before the air reaches the first reservoir. It is
distinctly different than a reservoir drain valve or aftercooler
in that it provides “dry air” for the air brake system. The
daily draining of the system’s reservoirs is no longer
necessary, thus reducing maintenance considerably when
compared to an air brake system without an air dryer.
In a system without an air dryer, the life of air brake
components is substantially reduced because of contact
with water and oil in the system and since the air dryer
removes water and oil in vapor form, life of the component
devices is substantially increased when the air dryer is used.

The air dryer can be used on most highway vehicles where
normal compressor loaded time is 90 seconds or less and
unloaded time is 30 seconds or more. If the compressor
remains loaded for long periods of time, such as on a transit
bus, certain changes in the purge volume of the dryer must
be made. For more information regarding increase of the
purge volume, contact our Engineering Department, in Elyria,
Ohio.
The air dryer is installed in the discharge line between the
compressor and the first reservoir. The unit must be mounted
vertically and mounting brackets are provided and can be
adjusted to meet installation requirements.
1

The housing assembly consists of two cylindrical steel
stampings welded together. For piping convenience, two inlet
ports, one reservoir port and one purge volume port are
provided in the AD-2™ air dryer. The side outlet port of the
AD-2™ air dryer incorporates an integral single check valve
with the top port used for the addition of purge volume.
(Refer to Figure 1)
A safety valve mounted in the housing assembly protects
against excessive pressure build-up within the housing.

The desiccant cartridge and aluminum oil separator filter
are removable and comprise a complete serviceable unit.
The desiccant beads, which are referred to as the “drying
bed”, are a drying substance that has the unique property
of exposing a tremendous surface area in proportion to its
bulk. One pound of the desiccant beads has about two
million square feet of adsorptive area made up of a large
number of submicroscopic cavities in each bead. Each
desiccant bead adsorbs or collects moisture.

The desiccant sealing plate assembly is located mid-way
in the housing assembly and houses a replaceable ball-type
single check. Also located in the plate assembly is the purge
orifice.

5-1/2”

PURGE
VOLUME

CHECK
VALVE
OUTLET
OUTLET

MOUNTING
BRACKET
LOCK
NUT
CHECK
VALVE
PURGE
ORIFICE

LOCK
NUT
DESICCANT
SEALING
PLATE

“O” RING

SPRING
RETAINER

“O” RING
INLET
19-1/2”
SAFETY
VALVE

INLET

CARTRIDGE
BOLT

DESICCANT
MOUNTING
BRACKET
OIL
FILTER

“O” RING

RETAINING
RING

PERFORATED
PLATE
DESICCANT
CARTRIDGE

OIL
FILTER

PURGE
VALVE
PISTON

HEATER

CONTROL
PORT
HEATER
PURGE
VALVE

AD-1™ AIR DRYER
FIGURE 2 - SECTIONAL VIEWS
2

EXHAUST
DEFLECTOR

THERMOSTAT
ENCLOSURE
PURGE
VALVE

ELECTRICAL
TERMINAL

AD-2™ AIR DRYER

The desiccant beads are held in place by steel perforated
plates and filter cloths. The top plate is held in place by a
spring, and the bottom plate rests on a shoulder
approximately 1/8" from the bottom of cartridge housing.
The end cover assembly is retained by a lock ring, cap
screws and retainers and houses the purge valve and heater
assembly if so equipped.
The heater and thermostat assembly prevent freeze-up in
the purge drain valve when the dryer is used in severe winter
conditions. The heater and thermostat assembly is standard
in the AD-2™ air dryer and was optional equipment for the
AD-1™ air dryer. The 12 volt, 60 watt and 24 volt, 60 or 120
watt DC heater and thermostat assembly has an operating
range between 45°F and 85°F.
NOTE: The heater and thermostat assembly provided with
the AD-2™ air dryer has a 3/16" diameter threaded
electrical terminal protected by a boot. The AD-1™
air dryer assembly incorporates a #16 gauge lead
wire. Both types are serviceable. The heater and
thermostat assembly should be connected to the
“on” position of the engine control or ignition switch
and protected with the proper size fuse. For details
on installation, please refer to the “Installation”
section.

OPERATION
The operation of the air dryer can best be described by
separating the operation into two cycles; the charge cycle
and the purge cycle.
Charge Cycle (Figure 3) Compressor in Compressing Cycle
- With the compressor in its “loaded” or compressing cycle,
air from the compressor enters the air dryer through the
discharge line. When the air, along with the water and
contaminants, enter the air dryer, the velocity or speed of
the air reduces substantially and much of the entrained liquid
drops to the bottom or sump of the air dryer. The initial air
flow is toward the bottom of the dryer, but air flow direction
changes 180° at the bottom of the air dryer, dropping some
water and oil.
The air now passes through the oil separator filter which
removes oil and foreign material but does not remove water
vapor. At this point, the air remains saturated with water.
The filtered air and vapors penetrate the desiccant drying
bed and the adsorption process begins. Water vapor is
removed from the air by the desiccant.
The unsaturated “dry” air passes through the ball check
valve and purge orifice into the purge volume. From the
purge volume air flows through an outlet check valve, and
into the first reservoir.

NOTE: The AD-1™ air dryer does not incorporate an integral
outlet check valve. The single check valve in an
AD-1™ air dryer installation would be located in the
line between the AD-1™ air dryer outlet port and the
first reservoir.
Purge Cycle; (Figure 4) When desired system pressure is
reached, the governor cuts out, pressurizing the unloader
cavity of the compressor which unloads the compressor
(non- compressing cycle). The line connecting the governor
unloader port to the end cover purge valve port (bottom of
the air dryer) is also pressurized, opening the exhaust of
the purge valve to atmosphere. With the exhaust of the
purge valve open, contaminants in the discharge line and
dryer sump are purged, or forced past the open exhaust out
to atmosphere.
The reverse air flows across the desiccant and starts the
removal process of moisture from the desiccant surface.
Dry air flowing from the purge volume through the purge
orifice and across the drying bed further dries the desiccant.
The combination of these reverse flows strips the water
vapor from the desiccant (drying bed). This normally takes
between 15-30 seconds.
The desiccant becomes activated from this cycle and is
now ready for another charge cycle, which occurs when the
compressor returns to the compressing cycle. It is for this
reason the air dryer must be purged for 30 seconds, after
receiving moisture saturated air for a maximum of 90
seconds from a 12 CFM compressor.

WARNING!
This air dryer is intended to remove moisture and other
contaminants normally found in the air brake system. Do
not inject alcohol, anti-freeze, or other de-icing substances
into or upstream of the air dryer. Alcohol is removed by the
dryer, but reduces the effectiveness of the device to dry
air. Use of other substances can damage the air dryer and
may void the warranty.

PREVENTIVE MAINTENANCE AND CHECKING
SERVICEABILITY
Important: Review the warranty policy before performing
any intrusive maintenance procedures. An extended
warranty may be voided if intrusive maintenance is
performed during this period.
Every 900 operating hours or 25,000 miles or every three
(3) months:
1. Check for moisture in the air brake system by opening
reservoirs, drain cocks, or valves and checking for
presence of water. If moisture is present, the desiccant
may require replacement; however, the following
conditions can also cause water accumulation and
should be considered before replacing the desiccant:
3

AD-2™ AIR DRYER OPERATIONAL CHARGE CYCLE

- AIR PRESSURE

FIGURE 3

AD-2™ AIR DRYER OPERATIONAL PURGE CYCLE

- AIR PRESSURE

FIGURE 4
4

A. An outside air source has been used to charge the
system. This air did not pass through the drying
bed.

4. Check for excessive leakage at the purge valve by
coating the exhaust with a soap solution while the
compressor is loaded. (compressing air)

B. Air usage is exceptionally high and not normal for a
highway vehicle. This may be due to accessory air
demands or some unusual air requirement that does
not allow the compressor to load and unload
(compressing and non-compressing cycle) in a
normal fashion. Check for high air system leakage.

5. Check the operation of the safety valve by pulling the
exposed stem while the compressor is loaded.
(compressing air) There must be an exhaust of air while
the stem is held and the valve should reseat when the
stem is released.

C. The air dryer has been installed in a system that
has been previously used without an air dryer. This
type system will be saturated with moisture and
several weeks of operation may be required to dry it
out.
D. Location of the air dryer is too close to the air
compressor. Refer to “Installation” section.
E. In areas where more than a 30° range of temperature
occurs in one day, small amounts of water can
accumulate in the air brake system due to
condensation. Under these conditions, the presence
of small amounts of moisture is normal and should
not be considered as an indication that the dryer is
not performing properly.
Note also that a small amount of oil in the system
may be normal and should not, in itself, be considered
a reason to replace the desiccant; oil stained
desiccant can often function adequately.
2. Check mounting bolts for tightness.
3. Check the operation of the integral single check valve
in the AD-2™ air dryer or the “in line” check valve used
with the AD-1™ air dryer. Build the air system to governor
cut-out and observe the test air gauge installed in the
#1 reservoir. A rapid loss of pressure could indicate a
failed check valve. This can be confirmed by checking
at the purge valve exhaust. (Note: Purge valve will be

6. Check all lines and fittings leading to and from the air
dryer for leakage and integrity.
7. Check the operation of the end cover heater and
thermostat assembly during cold weather operation as
follows:
A. Electric Power to the Dryer
With the ignition or engine control “on”, check for
power at the dryer’s electrical terminal (see Figure
16) with a voltmeter or test light. If there is no voltage,
look for a blown fuse, broken wires, or corrosion in
the vehicle wiring harness.
B. Thermostat and Heater
1. Turn off the ignition switch and cool the end cover
assembly to below 40°F. With an ohmmeter check
the resistance between the electrical terminal and
the aluminum of the end cover (see Figure 16).
This resistance should be 2.0 - 4.0 ohms for a
12 volt end cover, 8.1 -13 ohms for a 24 volt, 60
watt cover, and 4.0 - 7.0 ohms for a 24 volt, 120
watt end cover.
2. Warm the end cover assembly to over 90°F. and
check the resistance as above. This resistance
should exceed 1,000 ohms.
If these resistances are within the limits, the
thermostat and heater are operating properly.
If these resistances are outside the limits,
proceed to Step C to determine the cause.
C. Heater Element
With the ignition or engine control switch “off”,
remove the thermostat cover (see Figure 17). With
an ohmmeter check the resistance between the
aluminum of the end cover and the heater post (see
Figure 17). For a 12 volt end cover, the resistance
should be 2.0 - 2.8 ohms. For a 24 volt, 60 watt end
cover, 8.1 - 11.1 ohms, and for a 24 volt, 120 watt
end cover, 4.0 - 4.6 ohms. If the heater resistance
is outside these ranges, a new or remanufactured
end cover should be installed, since the heater
element cannot be serviced.

FIGURE 5

open when governor cut-out pressure is reached. Allow
two minutes for purge cycle before testing the check
valve.)

If the heater resistance is within the limits the
thermostat should be replaced (Kit Number 102637)
or a new or remanufactured end cover installed.

5

D. Reassembly
Reinstall the thermostat cover according to Figure
17. Take special care to assure the rubber spacer
and the gasket are correctly installed, to assure
proper operation.
8. Every 7200 hours; 200,000 miles or every 24 months,
change the desiccant cartridge.
NOTE: The desiccant change interval may vary from vehicle
to vehicle. Although typical desiccant cartridge life
is two years, many will perform adequately for three
to four years. In order to take maximum advantage
of desiccant life and assure that replacement
occurs only when necessary, it is important that
Serviceability Checks 1 - 7 be performed.

WARNING! PLEASE READ AND FOLLOW
THESE INSTRUCTIONS TO AVOID
PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following
general precautions should be observed at all times.
1. Park the vehicle on a level surface, apply the parking
brakes, and always block the wheels. Always wear
safety glasses.
2. Stop the engine and remove ignition key when
working under or around the vehicle. When working
in the engine compartment, the engine should be
shut off and the ignition key should be removed.
Where circumstances require that the engine be in
operation, EXTREME CAUTION should be used to
prevent personal injury resulting from contact with
moving, rotating, leaking, heated or electrically
charged components.
3. Do not attempt to install, remove, disassemble or
assemble a component until you have read and
thoroughly understand the recommended
procedures. Use only the proper tools and observe
all precautions pertaining to use of those tools.
4. If the work is being performed on the vehicle’s air
brake system, or any auxiliary pressurized air
systems, make certain to drain the air pressure from
all reservoirs before beginning ANY work on the
vehicle. If the vehicle is equipped with an AD-IS™
air dryer system or a dryer reservoir module, be
sure to drain the purge reservoir.
5. Following the vehicle manufacturer’s recommended
procedures, deactivate the electrical system in a
manner that safely removes all electrical power from
the vehicle.
6. Never exceed manufacturer’s recommended
pressures.
7. Never connect or disconnect a hose or line
containing pressure; it may whip. Never remove a
component or plug unless you are certain all system
pressure has been depleted.

6

8. Use only genuine Bendix® replacement parts,
components and kits. Replacement hardware,
tubing, hose, fittings, etc. must be of equivalent size,
type and strength as original equipment and be
designed specifically for such applications and
systems.
9. Components with stripped threads or damaged parts
should be replaced rather than repaired. Do not
attempt repairs requiring machining or welding
unless specifically stated and approved by the
vehicle and component manufacturer.
10. Prior to returning the vehicle to service, make
certain all components and systems are restored to
their proper operating condition.

REPLACING OR REBUILDING THE AD-1™ AND
AD-2™ AIR DRYER
GENERAL
If, after completing the routine serviceability tests, it has
been determined that one or more components of the air
dryer requires replacement or maintenance, refer to page
13 to ascertain the appropriate kit(s) needed. When rebuilding
or replacing components of the air dryer use only genuine
Bendix replacement parts or kits.

REMOVAL OF DESICCANT CARTRIDGE AD-1™ & AD-2™
AIR DRYER
CAUTION!
1. Loosen the air line to the control port of air dryer and
allow the trapped air to escape to atmosphere. After
the air escapes, remove the control line from the air
dryer.
2. Loosen the delivery line from the delivery port or outlet
of the air dryer. After the pressure drops, remove the
delivery line. Loosen the delivery check valve from this
port to relieve any trapped air above the desiccant plate
assembly. If the AD-1™ air dryer has an external check
valve at the delivery port loosen it to relieve air pressure.
3. Disconnect the heater wire.
4. Remove any exhaust silencers or the exhaust check
valve cover from the base of the air dryer. Using a hex
socket and wrench, loosen the purge valve assembly
and allow any trapped air to escape. Slowly unscrew the
purge valve and remove it.
5. Check all ports to insure that air is not trapped in the air
dryer by powdered desiccant material.
Air Dryer End Cover Removal Procedure
Warning - The AD-2™ air dryer cartridge contains a high
spring load. When replacing the AD-2™ air dryer cartridge or
performing any maintenance requiring end cover removal
follow the procedure outlined below.

End Cover Removal
1. Loosen the three cap screws on the end cover and turn
the retaining clamps aside (cap screws may be left
finger tight).
2. Locate the notch in the air dryer shell. While pushing the
end cover up into the dryer, insert the blade of a
screwdriver in the notch and slowly pry out the retaining
ring. If the cartridge bolt has loosened the cartridge
spring may exert a force on the end cover retaining ring
making removal of the retaining ring and end cover
difficult. This spring force will prohibit the end cover
moving up into the dryer shell when pushed up. Warning:
This same force can also cause the end cover to come
out of the air dryer shell unexpectedly during the removal
process. Exercise extreme caution to prevent bodily
injury.
3. Do not stand or lay directly under the end cover while
servicing. Assure adequate clearance between the end
cover and other surfaces to prevent hand injury if the end
cover dislodges rapidly during removal. NOTE: BE
CERTAIN THE DESICCANT SEALING PLATE
ASSEMBLY COMES OUT WITH THE CARTRIDGE.

the plate is removed. In the past, three methods have been
employed, to secure the desiccant sealing plate to the
desiccant cartridge: a Tru Arc retaining ring, two special
thin nuts, and the latest method, a single hex lock nut.
Removing the securing device will permit the desiccant plate
to be separated from the desiccant cartridge. After removing
the desiccant cartridge:
1. Remove the two o-rings from the desiccant plate and
discard them.
2. Remove the ball check valve retaining clip and remove
and discard the rubber ball valve.
3. Clean the desiccant plate thoroughly using a quality
commercial solvent, making sure the purge orifice and
check valve seat are clean.
4. Install a new ball check valve and replace the retaining
clip and screw (Figure 5).
5. Thoroughly lubricate the two new o-rings and install them
in their respective grooves in the purge plate (Figure 6).
6. Set the desiccant sealing plate aside for reinstallation
on the desiccant cartridge.

CAUTION: Before attempting to remove the desiccant
sealing plate, measure the cartridge bolt from
the top of the desiccant plate lock nut to the
end of the bolt threads. If that measurement is
approximately 3-3/16 inches, proceed with the
disassembly.
If the bolt measures approximately 1-9/16
inches, disassemble using CAUTION.
Approximately 75 pounds of spring force will
remain against the desiccant plate when the lock
nut reaches the end of the bolt thread and is
removed.

REMOVING AND REBUILDING THE AD-1™ AND
AD-2™ AIR DRYER DESICCANT SEALING PLATE
Before the desiccant cartridge can be replaced or rebuilt
the desiccant sealing plate must be removed. It is
recommended that all non-metallic parts be replaced when

FIGURE 7 - REPLACEMENT DESICCANT CARTRIDGE
FIGURE 6 - DESICCANT SEALING PLATE
7

REINSTALLING THE DESICCANT CARTRIDGE
AD-1™ AND AD-2™ AIR DRYER
If the desiccant cartridge is to be replaced as an assembly
rather than rebuilt (see desiccant cartridge rebuilding
instructions), the cartridge removed from the air dryer.
The current revision replacement desiccant cartridge is
shown in Figure 7. All prior revisions of the cartridge will
interchange with no modifications to either air dryer.
Prior to installing the new replacement cartridge in the air
dryer, the following steps must be followed:
1. Carefully remove the lock nut from the cartridge bolt
using an 11/16 in. open end or box wrench. IMPORTANT:
Care must be taken not to allow the cartridge bolt to slip
out of the cartridge when the lock nut is removed. Loss
of desiccant material will occur should this happen.
2. Install the previously rebuilt desiccant sealing plate on
the cartridge bolt so that the ball check retaining clip
remains visible (see Figure 15-1 & 15-2).
3. While holding the cartridge bolt reinstall the lock nut on
the cartridge bolt. IMPORTANT: Before tightening the
lock nut down make certain that the shoulder (the
unthreaded portion) of the cartridge bolt extends slightly
above the perforated desiccant plate (see Figure 12).
4. By tightening the lock nut, draw the desiccant sealing
plate down into the desiccant cartridge until the shoulder
of the desiccant sealing plate is against the cartridge
shell. (See Figure 15)

REBUILDING THE DESICCANT CARTRIDGE
IMPORTANT: Only the current revision desiccant cartridges
(See Figure 7) can be rebuilt. Current revision desiccant
cartridges are identified positively by the Bendix trademark
BW stamped in the hex head of the cartridge bolt, and by
the letters and number AD-2™ air dryer displayed on the
bottom face of the oil filter. If an old revision desiccant
cartridge is removed from the air dryer, it should be
replaced with a complete current revision desiccant
cartridge.

FIGURE 8 - ASSEMBLY OF DESICCANT CARTRIDGE
8

FIGURE 9

DISASSEMBLY OF DESICCANT CARTRIDGE
1. Carefully remove and discard the lock nut on top of the
desiccant sealing plate. (The plate is spring loaded; see
“Caution” note in “Removal of Desiccant Cartridge”
section.)
2. Remove the desiccant sealing plate and rebuild it as
outlined under the Removing and Rebuilding the
Desiccant Sealing Plate section of this manual.
3. Remove and retain the spring, spring seat, bolt, and
cartridge shell. Discard the oil separator filter, the two
perforated plates and desiccant material.

FIGURE 10

4. Insert one of the perforated plates into the cartridge,
cloth side up, and tap it firmly to the bottom. (Cloth
always faces desiccant material.) (See Figure 8)

FIGURE 12

FIGURE 11

5. Slide oil separator filter over the cartridge bolt with the
gasket surface next to the shell. (See Figure 9)
6. Install the bolt with the oil separator into the bottom of
the shell and through center hole of the perforated plate
in the bottom of the shell. (See Figure 10)
7. Pour the entire package of desiccant material into the
shell, making sure none is lost. Handle carefully so
that the bolt does not fall out. (See Figure 11)
8. Level the desiccant material and install second
perforated plate cloth side down. (Make sure the
shoulder of the bolt is centered, and extends slightly
above the top of the perforated plate.) (See Figure 12)
NOTE: If the shoulder of the bolt does not extend above
the perforated plate tap the side of the desiccant
container.
9. Set the conical spring on top of the perforated plate
(large diameter down - small diameter up.)
10. Place the spring retainer on top of the spring (See Figure
13)
11. Install the previously rebuilt desiccant sealing plate on
the cartridge bolt so that the ball check retaining clip is
in view.
12. Using the lock nut draw the assembly together to
approximately half of the spring’s free height. While
slowly turning the cartridge, tap the side of the shell
with a plastic mallet (See Figure 14). This allows the
desiccant material to settle properly into place. Continue
to tighten the nut, making sure all items are properly
aligned. Tighten nut firmly using an 11/16" socket or
box wrench. (See Figures 15-1, 15-2)
FIGURE 13
9

DISASSEMBLY
REBUILDING THE AD-1™ AIR DRYER END
COVER ASSEMBLY
To remove the end cover assembly from the air dryer follow
steps 1-6 under the section of this manual entitled Removal
of Desiccant Cartridge AD-1™ and AD-2™ air dryer. Before
rebuilding the end cover, clean the exterior thoroughly using
a quality commercial solvent.
1. Remove and discard the large o-ring around the end
cover.
2. Remove the exhaust elbow and clamp.
3. Remove the cap nut and discard the cap nut o-ring.
4. Place the handle of a large screwdriver in a vise and
secure it.
5. Place the slot in the plunger (cap nut end) over the blade
of the screwdriver, hold it securely and remove the nut
from the plunger using a 1/2" socket wrench.

FIGURE 15-1

6. Remove the plunger, spring and valve. Discard the valve.
7. Clean and inspect the plunger bore and the valve seat.
8. Remove and discard the three o-rings from the plunger.
Clean the plunger.
NOTE: If during the serviceability checks it was determined
that the heater and thermostat were defective, use
the following procedure. It is not necessary to
replace this assembly each time the purge valve is
rebuilt.

FIGURE 15-2

11. Remove the square cut seal ring at the bottom of the
thermostat bore.
12. Remove the screw, retaining clip, o-ring, and the heater
element. Inspect the bore for corrosion and if necessary,
clean it.
FIGURE 14

9. Remove the two screws that secure the shield or
thermostat retaining clip to the end cover.
10. Remove the shield or clip and the thermostat and inspect
the bore for corrosion.
10

ASSEMBLY
13. Install the heater element, securing it in the end cover
with the retainer clip and screw.
14. Install the square cut seal ring in the thermostat bore.

16. Lubricate and install the o-rings on the plunger and cap
nut.

NOTE: If during the serviceability checks it was determined
that the thermostat was defective, use the following
procedure. It is not necessary to replace this unit
each time the end cover is rebuilt. Use thermostat
kit. (See Figure 17)

17. Lubricate the plunger bore and install the spring and
plunger (through the cap nut end).

9. Remove nut(2), then lockwasher(3), plain washer(4) and
o-ring(5). Discard o-ring and retain other parts.

18. Install the valve on the plunger, making certain the
chamfered end of the valve is in contact with the metal
seat of the body.

10. Remove and retain four Phillips head screws(7) and
cover(6).

19. Using the screwdriver held in the vise, as described in
Steps 4 & 5, compress the plunger into the bore while
installing and tightening the nut.

12. Remove and retain spacer(11).

15. Install the thermostat metal side down in the end cover
bore and secure it in place using the retaining clip or
shield and the two screws.

20. Install the cap nut and tighten it.

11. Remove and discard gasket(10).
13. Cut uninsulated thermostat wire at Point B. (Figure 17),
remove and discard thermostat and terminal
assembly(1).

21. Lubricate and install the large diameter o-ring around
the end cover assembly.

14. Clean remaining wire attached to heater terminal.

REBUILDING THE AD-2™ AIR DRYER END
COVER

ASSEMBLY

ASSEMBLY
To remove the end cover assembly from the air dryer follow
steps 1-6 under the section of this manual entitled Removal
of Desiccant Cartridge AD-1™ and AD-2™ Air Dryer. Before
rebuilding the end cover, clean the exterior thoroughly using
a quality commercial solvent.
DISASSEMBLY
1. Remove and discard the large o-ring around the end
cover assembly.
2. Remove the single #6-32 screw securing the exhaust
diaphragm and separate the diaphragm, washer and
screw. Discard the diaphragm.
3. Remove the three #6-32 screws securing the exhaust
cover and remove the exhaust cover.
4. Remove the purge valve assembly, the large hex cap
nut, from the end cover and discard both o-rings around
the cap nut.
5. Using a 7/16" socket wrench and a large screwdriver,
remove the 1/4"-20 hex head cap screw which holds
the assembly together.
6. Separate cap screw, purge valve, purge valve piston
and the piston return spring.

15. Clean thermostat “pocket” in end cover(9).

16. Cut uninsulated lead of new thermostat(1) at Point A
(Figure 17).
17. Install thermostat in end cover “pocket” and position
uninsulated leads next to each other.
18. Using a soldering heat sink, clamp uninsula-leads at
Point B and solder leads with straight rosin core solder.
DO NOT USE ACID CORE SOLDER. Clean excess
solder off end cover.
19. Install thermostat terminal(1) in cover(6).
20. Install o-ring(5), washer(4), lockwasher(3) and nut(2).
Torque nut to 20-30 inch pounds.
21. Install spacer(11) over thermostat(1).
22. Install gasket(7) and cover(6) and secure cover to end
cover(9) using screws(7) and lockwashers(8).
23. Torque to 30-40 inch pounds.
24. Test thermostat as follows:
A. At a temperature above 85°F. check resistance
between thermostat terminal(1) and end cover(9).
Resistance should be 200,000 ohms or greater; if
not, check for solder “path” short.
B. Chill entire end cover assembly to 35°F. or below
and check resistance again. Resistance should be
2-15 ohms.

7. Discard the piston o-ring, the purge valve, and the piston
return spring.

25. Lubricate the piston o-ring and install it on the piston.

8. Wash all remaining parts in a commercial solvent, making
sure all surfaces, bores, ports, and passages are clean
and dry before assembly.

27. Install the purge piston return spring and piston.

26. Lubricate the piston bore.
28. Install the purge valve in the large cap nut so that the
rubber portion rests on the metal seat of the cap nut.
29. Secure the valve to the piston using the 1/4"-20 cap
screw and lockwasher and torque to 50 inch pounds.
30. Lubricate and install the two cap nut o-rings.
11

FIGURE 16 - AD-2™ AIR DRYER END COVER

31. Lubricate the cap nut threads and the cap nut bore of
the end cover and install the cap nut, torquing it to
180-250 inch pounds.
32. Secure the exhaust diaphragm to the exhaust cover using
the #6-32 Phillips head screw and diaphragm washer.
33. Secure the exhaust cover to the purge valve hex head
cap nut using the #6-32 Phillips head screws.
34. Lubricate and install the large diameter o-ring around
the end cover assembly.

REBUILDING THE AD-2™ AIR DRYER OUTLET
PORT CHECK VALVE
1. Make certain the vehicle is safely parked. Block the
wheels if necessary.
2. Locate and remove the line connected to the outlet port
of the AD-2™ air dryer.
3. Remove the check valve from the outlet port. (See Figure
2)

4. Remove the rubber sealing ring from the external
threaded portion of the body and discard it.
5. Disassemble the check valve by unscrewing the body
halves and note the order of the removal of the parts.
6. Discard and replace the check valve, valve spring and
metal seal washer.
7. Wash all parts in a quality commercial solvent, making
sure all surfaces are clean and dry prior to reassembly.
8. Coat all parts with a film of barium base lubricant such
as Bendix piece number 246671 which is supplied with
the maintenance kit.
9. Reassemble the check valve and torque the body halves
to between 200 and 225 inch pounds.
10. Reinstall the check valve in the AD-2™ air dryer outlet
port and reconnect the line leading to the first reservoir.

REINSTALLING THE DESICCANT CARTRIDGE
AD-1™ AND AD-2™ AIR DRYER
1. Wipe the inside of the dryer clean. If a solvent is used,
be certain that no residue is left in the shell.

HEATER POST
9
1
9
A
B

8
10
5

3
THERMOSTAT 2
1 COVER
FIGURE 17
12

7
1

4

6

11

2. Check to be certain a film of barium base grease is
present on the o-rings and install the cartridge and purge
plate assembly into the body. Engage the bolt and tighten
to 375 inch pounds or 32 foot pounds torque.
3. Check the end cover o-ring to be certain it is clean and
lubricate the o-ring with a barium base lubricant such as
Bendix 246671. Install the o-ring on the end cover and
install the end cover in the dryer body.

4. Position the end cover as marked during removal and
install the retainer ring so that the gap in the ring is
within an inch of the notch in the body.
5. Grease the threads on the three cap screws and reinstall
them with their retainers in the end cover.
6. Reconnect the air control line to the purge valve port in
the end cover.
7. Reconnect the thermostat and heater wire.
8. Test the air dryer as outlined under the Preventive
Maintenance and Checking Serviceability Section of this
manual.

INSTALLATION OF AD-1™ AND AD-2™ AIR
DRYER
1. Install the air dryer in the compressor discharge line as
close to the supply (first) reservoir as possible. The
discharge line between the compressor and air dryer
must not exceed 20 feet in length nor less than six feet
in length for a two cylinder compressor or ten feet in
length for a single cylinder compressor. Six feet of
discharge line and a 90 cubic inch reservoir can be used
in lieu of ten feet of discharge line for single cylinder
compressors.
The discharge line should slope downward from the
compressor to the air dryer inlet to avoid water traps
and to allow drainage to the air dryer. (If the 90 cubic
inch reservoir is used, it should also be mounted and
plumbed to avoid water traps and to allow drainage into
the air dryer.) Discharge lines may be either be copper
tubing or high temperature hose. However, Bendix
compressors require a minimum of four feet of copper
tubing extending from the discharge port. The balance
of the discharge line may be either copper tubing or
high temperature hose.

terminal. This connection must be waterproof. Use an 8
to 10 amp. fuse with 12 volt end covers and with 24 volt
end covers identified with the marking “24V 120W.” Use
a 4 to 5 amp. fuse with 24 volt end covers identified with
the marking “24V.”
IMPORTANT NOTE: A new 24 volt heater was
introduced in 1983. The new heater version draws
120 watts of power and requires an 8 to 10 amp fuse.
End covers with the new heater are identified with
the marking “24V 120W” cast on the identification
boss of the end cover. The previous identification
was “24V”.

MAINTENANCE KIT FOR THE AIR DRYER
286718 DESICCANT CARTRIDGE REFILL KIT
This kit can only be used on new revision cartridges.
See the cartridge rebuild section of this manual for
proper identification of current revision cartridge.
This kit contains the necessary parts to rebuild the
cartridge and the desiccant sealing plate.
287313 DESICCANT CARTRIDGE REPLACEMENT KIT
This kit contains a factory replacement desiccant
cartridge and the parts necessary to rebuild the
desiccant sealing plate.
285519 AD-1™ AIR DRYER PURGE VALVE MAINTENANCE
KIT
This kit contains the parts necessary to rebuild the
AD-1™ air dryer end cover purge valve only.
287053 AD-2™ AIR DRYER PURGE VALVE MAINTENANCE
KIT
This kit contains the parts necessary to rebuild the
AD-2™ air dryer end cover purge valve.

2. Locate outside the engine compartment in an area of
air flow when the vehicle is in motion. Do not mount
near exhaust system or other heat-producing
components and avoid road-splash areas. Provide 20
cm (8 in.) clearance below dryer for servicing.

287298 AD-2™ AIR DRYER CHECK VALVE MAINTENANCE
KIT
This kit contains the components necessary to
rebuild the inline single check valve that is used in
AD-1™ air dryer installations must be serviced
separately.

3. Mount vertically, with purge valve exhaust toward the
ground, away from the frame and other components.
Connect a hose to the exhaust cover if necessary, since
this valve may expel rust and scale particles as well as
condensate and oil collected in the dryer.

288918 THERMOSTAT COVER REPLACEMENT KIT
This kit contains the parts required to replace the
non-metallic thermostat cover only. This kit is used
to replace a damaged cover and does not
contain thermostat parts.

4. Connect the purge valve control port to one of the
governor unloader ports. This line should be routed such
that no water traps are formed.

102657 THERMOSTAT MAINTENANCE KIT
This kit contains the necessary components to
rebuild the thermostat assembly in the AD-2™ air
dryer.

5. For the dryers with a 3/4-14 or 1 - 11-1/2 dryseal outlet
port, a check valve must be placed between the purge
volume and the first downstream reservoir. (Dryers with
1/2-14 dryseal outlet ports have a built-in check valve.)
6. Connect a fused #16 gauge wire from the “on” position
of the engine control or ignition switch to the heater

101900 REMANUFACTURED DESICCANT CARTRIDGE
AND DESICCANT SEALING PLATE.
This unit allows for complete exchange, as a unit,
of the cartridge and desiccant plate.
13

COMPRESSOR
GOVERNOR
UNLOADER

AD-2™
AIR
DRYER

RESERVOIR #1

TO NO. 2
RESERVOIR

SAFETY VALVE

PURGE DRAIN
VALVE
#16 GAGE WIRE
TO IGNITION

FIGURE 18 - TYPICAL INSTALLATION FOR THE AD-2™ AIR DRYER

COMPRESSOR
GOVERNOR
UNLOADER

AD-1™
AIR
DRYER

RESERVOIR #1

TO NO. 2
RESERVOIR

CHECK VALVE*
SAFETY VALVE

PURGE DRAIN
VALVE
HEATER

#16 GAGE WIRE
TO IGNITION

* (NOTE) A CHECK VALVE MUST BE PLACED BETWEEN THE AIR DRYER AND NO.1 RESERVOIR

FIGURE 19 - TYPICAL INSTALLATION FOR THE AD-1™ AIR DRYER
14

AD-2™ AIR DRYER TROUBLESHOOTING CHART
SYMPTOM
1. Dryer is constantly
“cycling” or purging.

2. Water in vehicle
reservoirs.

CAUSE
A.

Excessive system leakage.

A.

B.

B.

C.

Excessive leakage in fittings, hoses
and tubing connected to compressor,
air dryer and first reservoir.
Defective check valve between air dryer
and first reservoir. (In standard AD-2™
air dryer, check valve to outlet port.)

C.

D.

Defective governor.

D.

E.

Leaking purge valve in air dryer end
cover (control side).

E.

F.

Compressor unloader mechanism
leaking excessively.

F.

A.

Desiccant requires replacement.

A.

Replace desiccant cartridge.

B.

Improper discharge line length or
improper line material.

B.

C.

Air system charged from outside air
source (outside air not passing
through air dryer).

C.

D.

Air dryer not purging (see Symptom
#5).
Purge (air exhaust) time insufficient
due to excessive system leakage
(see causes for Symptom #1).
Air dryer/vehicle application requires
additional purge volume.

D.

Minimum of six-foot metal tubing for
two-cylinder compressor; ten-foot for
one-cylinder compressor. Flex hose
can be substituted at ratio of 1-1/2' flex hose for
each 1' of metal.
If system must have outside air fill provision,
outside air should pass through air dryer.
(Unused inlet on air dryer can be used.) Use of
this should be minimized.
See cause and remedy for Symptom #5.)

E.

Check causes and remedies for Symptom #1.

F.

When compressor is loaded (compressing)
longer than 90 seconds during normal
operation, additional purge volume may be
needed. (Before proceeding, contact Bendix
representation for consultation.)
Air dryer requires minimum purge time of 30
seconds. If compressor stays loaded longer
than 90 seconds and additional purge volume is
added, longer purge time is required. Air dryer
efficiency will decrease as compressor
loaded time increases beyond 120 seconds,
during normal operation of the vehicle. (This
limitation assumes a compressor of
approximately 12 CFM and engine operation at
1600-1900 RPM.) The air dryer will
accommodate occasional longer loaded times,
such as initial system build-up.

E.
F.

3. Safety valve on air dryer
“popping off” or
exhausting air.

REMEDY

G.

Air dryer not compatible with vehicle
air system requirement - (Improper air
dryer/vehicle application).

G.

A.

Desiccant cartridge plugged or
saturated.

A.

B.

Defective check valve between air
dryer outlet port and first reservoir. (in
standard AD-2™ air dryer, check valve
in outlet port.)
Defective fittings, hose or tubing
between air dryer and first reservoir.

B.

C.

C.

Test for excessive leakage and repair.
Allowable leakage:
Pre-121 vehicles, single vehicle - 2 psi/minute.
Tractor trailer - 3 psi/minute.
121 vehicles, single vehicle - 1 psi/minute per
service reservoir.
Tractor trailer - 3 psi/minute per service
reservoir.
Using soap solution, test for leakage at fittings,
drain valve (if any) and safety valve in first
reservoir. Repair or replace as necessary.
Test check valve. Leakage should not exceed
1" soap bubble in five seconds. It may be
necessary to remove check valve to test.
Repair or replace as necessary.
Test governor for proper cut-in or cut-out
pressures and excessive leakage in both
positions.
Remove end cover. Apply 120 psi at control
port. Soap both sides around purge valve to test
for control piston leakage.
(Permissible leakage - 1" bubble in 5 seconds.)+`
Remove air strainer or fitting from compressor
inlet cavity. With compressor unloaded, check
for unloader piston leakage.
Slight leakage permissible.

Check compressor for excessive oil passing
and/or correct compressor installation. Repair
or replace as necessary.
Rebuild or replace cartridge.
Test to determine if air is passing through
check valve. Repair or replace.
Check to determine if air is reaching first
reservoir. Inspect for kinked tubing or hose.
Check for undrilled or restricted hose or tubing
fittings.

15

SYMPTOM
4. Constant exhaust of air
at air dryer purge valve
exhaust or unable to
build system pressure.

CAUSE
A.
B.
C.
D.
E.
F.
G.

5. Air dryer does not purge
or exhaust air.

6. Desiccant material being
expelled from air dryer
purge valve exhaust
(may look like whitish
liquid or paste or small
beads).

OR
Unsatisfactory desiccant
life.

Air dryer purge valve leaking
excessively.
Defective governor.
Purge control line connected to
reservoir or exhaust port of governor.
Purge valve frozen open - faulty
heater and thermostat, wiring, blown
fuse.
Inlet and outlet air connections
reversed.
Check valve between air dryer and first
reservoir defective.
Kinked or blocked (plugged)
discharge line.

REMEDY
A.
B.
C.
D.
E.
F.
G.

With compressor loaded, apply soap solution
on purge valve exhaust, to test for excessive
leakage. Repair purge valve as necessary.
Check governor for proper “cut-in”, “cut-out”
pressure and excessive leakage in both
positions. Repair or replace as necessary.
Purge control line must be connected to
unloader port of governor.
Test heater and thermostat as described in
Step 7 of Preventive Maintenance Section.
Compressor discharge to inlet port. Reconnect
lines properly.
Test check valve for proper operation (see
Symptom #3, Remedy B).
Check to determine if air passes through
discharge line. Check for kinks, bends,
excessive carbon deposits.
Discharge line should be constantly sloping
from compressor to air dryer with as few bends
as possible.
See Symptom #1’s Causes and Remedies.

H.

Excessive bends in discharge line
(water collects and freezes).

H.

I.

Excessive system leakage.

I.

A.

Broken, kinked, frozen, plugged or
disconnected purge control line.

A.

B.

Faulty air dryer purge valve.

B.

C.

See Causes B,E,F,G,H, for Symptom
#4.

C.

A.

This symptom is almost always
accompanied by one or more of
Symptoms 1,2,3,4 and 5. See related
causes for these Symptoms above.

A.

See Causes and Remedies for Symptoms 1,2,3,4
and 5.

B.

Air dryer not securely mounted.
(Excessive vibration).

B.

Vibration should be held to minimum. Add
bracket supports or change air dryer mounting
location if necessary.

C.

Defective cloth covered perforated
plate in air dryer desiccant cartridge
or improperly rebuilt desiccant
cartridge.
Compressor passing excessive oil.

C.

Replace or rebuild desiccant cartridge. NOTE:
If rebuilding cartridge, carefully follow
instructions packed with cartridge rebuild kit.

D.

D.

Test to determine air flows through purge
control line when compressor unloaded. Check
for undrilled fittings. (See Symptom #4,
Remedy C.)
After determining air reaches purge valve
(Remedy A above), repair purge valve.
Refer to Remedies B, E, F, G, H, for Symptom
#4.

E.

Faulty heater and thermostat, wiring,
fuse not allowing purge. (Cold weather
operation only.)

E.

Check for proper compressor installation; if
symptoms persist, replace compressor.
Refer to Remedy D under Symptom #4.

7. Unable to remove end
cover, or unable to install
new desiccant cartridge.

A.

Result of reversing the inlet and outlet
connections. (See Symptom #4,
Cause E.)

A.

Refer to Symptom #4, Cause E.

8. Air dryer end cover
separates from air dryer
housing during operation.

A.

Excessive system pressure build up
within air dryer; caused by either
plugged desiccant, check valve failure,
frozen or obstructed discharge line
(between air dryer and first reservoir) or
governor failure in conjunction with
safety valve failure.

A.

Because it is difficult to determine extent of
internal damage to air dryer, it is recommended
that the air dryer be replaced.
NOTE: This type of failure can be prevented by
checking the dryer for proper operation every
three (3) months.

BW1597 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 7/2004 Printed in U.S.A.

16



---

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.3
Linearized                      : Yes
Create Date                     : 2005:01:06 14:01:15-05:00
Modify Date                     : 2005:01:06 14:01:15-05:00
Subject                         : Sd082403
Page Count                      : 16
Creation Date                   : 2005:01:06 19:01:15Z
Mod Date                        : 2005:01:06 19:01:15Z
Producer                        : Acrobat Distiller 5.0.5 (Windows)
Author                          : BENDIX COMMERCIAL VEHICLE SYSTEMS LLC
Keywords                        : 
Metadata Date                   : 2005:01:06 19:01:15Z
Creator                         : BENDIX COMMERCIAL VEHICLE SYSTEMS LLC
Title                           : Sd082403
Description                     : Sd082403

EXIF Metadata provided by EXIF.tools